WO2007056833A1 - Cast in situ concrete slab - Google Patents
Cast in situ concrete slab Download PDFInfo
- Publication number
- WO2007056833A1 WO2007056833A1 PCT/AU2006/001760 AU2006001760W WO2007056833A1 WO 2007056833 A1 WO2007056833 A1 WO 2007056833A1 AU 2006001760 W AU2006001760 W AU 2006001760W WO 2007056833 A1 WO2007056833 A1 WO 2007056833A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- concrete
- sheets
- pans
- side edge
- slab
- Prior art date
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
- E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
- E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
- E04B5/36—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
- E04B5/38—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element
- E04B5/40—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element with metal form-slabs
Definitions
- the present invention relates to cast in situ concrete slabs, hereinafter referred to as "concrete slabs" for use in the building industry.
- the present invention relates particularly, although by no means exclusively, to concrete slabs for use in the construction of mezzanine floors and floors for multi-storey buildings, including multi-storey car parks.
- the present invention also relates to assemblies of two or more components of concrete slabs .
- concrete slabs In the context of the construction of floors, the term “concrete slabs” is understood herein to mean slabs that include (a) a base formed from a plurality of profiled decking sheets positioned in side-by-side and/or end-to-end relationship as required; and (b) a layer of concrete on the base .
- concrete slabs is understood herein to mean slabs that also include reinforcement embedded in the concrete layer .
- the profiled decking sheets of the concrete slabs may contribute to the mechanical performance of the concrete slabs. Specifically, the profiled decking sheets may act compositively with the concrete via mechanical bonding and therefore contribute to the bottom reinforcement of the concrete slabs .
- the present invention extends to arrangements in which the profiled decking sheets do not make a contribution to the mechanical performance of the concrete slabs and the profiled decking sheets act as lost formwork only.
- concrete floor slabs are formed in situ by (a) positioning a plurality of the profiled decking sheets onto a permanent support structure, such as a series of horizontal beams , and forming a continuous base (b) positioning formwork that defines the perimeter of the concrete slabs, (c) placing reinforcement, typically in the form of flat sheets of steel mesh or bars, or both mesh and bars , on or in relation to the profiled decking sheets, and (d) finally pouring concrete onto the assembly of the decking sheets and reinforcement within the perimeter of the formwork and forming a layer of concrete .
- a permanent support structure such as a series of horizontal beams
- the sheets may need to be propped temporarily between the permanent support members .
- profiled decking sheet is understood herein to mean roll-formed sheets or brake pressed sheets that include at least one pan and side edge formations that enable adjacent sheets to be positioned together in side-by-side relationship.
- profiled decking sheet In situations in which a profiled decking sheet includes two or more than two pans, the term "profiled decking sheet” is understood herein to include one or more than one upstanding rib separating adjacent pans.
- profiled decking sheets used in concrete slabs are supplied cut to lengths in the range of 0.4 to 19.5 m and widths in the range of 0.3 to 1.2 m.
- the maximum unsupported spans of profiled decking sheets used in concrete slabs are currently 6 m or more.
- the above-described maximum length and maximum width are set by issues relating to the structural performance of the profiled decking sheets as formwork, particularly the extent to which the profiled decking sheets can support the weight of wet concrete on sheets .
- the present invention is based on a realisation that longer unsupported spans and/or wider structural decking sheets can be used in concrete slabs by spacing the concrete layer above the pans of profiled decking sheets and forming a space between the pans of the profiled decking sheets and the concrete layer.
- a concrete slab that includes :
- each decking sheet including one pan and side edge formations that enable adjacent sheets to be positioned in side by side relationship, and
- a concrete slab that includes: (a) a base formed from a plurality of profiled decking sheets positioned side by side, with each decking sheet including two or more than two pans, an upstanding rib separating adjacent pans, and side edge formations that enable adjacent sheets to be positioned in side by side relationship, and
- the concrete layer is spaced at least 40 mm above the pans of the profiled decking sheets in a situation in which the thickness of the concrete slab is at least 140 mm.
- the concrete layer is spaced at least 60 mm above the pans of the profiled decking sheets in a situation in which the thickness of the concrete slab is at least 180 mm.
- the concrete slab includes a means that spaces the concrete layer above the pans of the base .
- the spacing means resists lateral deflection of side edge formations and/or ribs of the profiled decking sheets under load, for example an applied load of wet concrete .
- the spacing means may be one or more than one plate that extends between and is connected to adjacent side edge formations and/or ribs of the profiled decking sheets and forms a raised base for the concrete layer.
- the spacing means includes at least one block of a lightweight material positioned on at least one of the pans of at least one of the profiled decking sheets so that the block or blocks forms a raised base for the concrete layer .
- the lightweight material may be any suitable material .
- the lightweight material is polystyrene foam.
- the block of the lightweight material and (b) the side edge formations and/or the ribs of the decking sheets on opposite sides of the block are mechanically interlocked or otherwise engaged together to resist lateral deflection of side edge formations and/or ribs of the profiled decking sheets under load.
- ⁇ dhesives are one example of a form of engagement between the block of the lightweight material and the side edge formations and/or the ribs of the decking sheets
- the block of the lightweight material and the side edge formations and/or the ribs of the decking sheets may become mechanically interlocked together after there has been a predetermined amount of lateral deflection of the side edge formations and/or the ribs of the decking sheets in response to load on the profiled decking sheets due to weight of wet concrete that is poured onto the profiled decking sheets in the process of forming a concrete slab .
- the block of the lightweight material When the block of the lightweight material is mechanically interlocked or otherwise engaged with the side edge formations and/or the ribs of the profiled decking sheets, it is not necessary that the block be adhered or otherwise secured to the pans of the decking sheets .
- the block or blocks of the lightweight material Preferably at least substantially cover the surface of the pans of the decking sheets. Consequently, there is no upward hydrostatic pressure on the block or blocks when the concrete is wet.
- the block or blocks of the lightweight material may be the same length as the profiled decking sheets .
- the block or blocks of the lightweight material may be shorter than the lengths of the profiled decking sheets and be positioned in end to end relationship on the pans of the decking sheets - to allow concrete to be placed in compression where necessary and to achieve full capacity of shear studs or other means of connecting the profiled decking sheets to a permanent support structure.
- the side edge formations and/or the ribs of the profiled decking sheets are at least 50 mm high.
- the side edge formations and/or the ribs of the profiled decking sheets are at least 60 mm high.
- the block or blocks of the lightweight material have a height that is at least 70% of the height of the side edge formations and/or ribs of the decking sheets .
- the block or blocks of the lightweight material are at least 50 mm high.
- the side edge formations and/or the ribs of the decking sheets are relatively high so as to provide an effective mechanical interlock with concrete of the concrete slab .
- the side edge formations are formed to allow engagement of side edge formations of adjacent profiled decking sheets that inhibits vertical and/or horizontal separation of the sheets .
- the side edge formations may be formed so that the side edge formations of adjacent profiled decking sheets engage each other in overlapping relationship .
- the side edge formations may be formed so that the side edge formations of adjacent profiled decking sheets engage without overlapping of the formations .
- An example of such an arrangement is one in which the side edge formations include a web that extends upwardly from a pan and includes a rib that is shaped so that the ribs of side edge formations of adjacent profiled decking sheets interlock.
- Such an arrangement is disclosed in International applications PCT/AUOl/01446 (WO02/38885) and PCT/AU2004/000366 (WO2004/085085) and the disclosure in these International applications is incorporated herein by cross-reference.
- the profiled decking sheets are pre- cambered along the length of the sheets .
- the profiled decking sheets are pre- cambered along the length of the sheets so that the pans of the sheets form flat, horizontal surfaces when wet concrete is poured to form the concrete slab.
- the concrete slab further includes reinforcement, such as steel mesh, embedded in the concrete .
- the reinforcement may be pretensioned.
- the reinforcement may be welded or otherwise connected to the side edge formations and/or the ribs of the profiled decking sheets to increase the resistance to lateral deflection under load.
- the spacing means resists lateral deflection of side edge formations and/or ribs of the profiled decking sheets under load, for example the applied load of wet concrete
- the spacing means may be one or more than one plate that extends between and is connected to adjacent side edge formations and/or ribs of the profiled decking sheet and forms a raised base for the concrete layer.
- the spacing means includes at least one block of a lightweight material that mechanically interlocks or otherwise mechanically engages side edge formations and/or ribs of the decking sheet on opposite sides of the block or blocks and forms a raised base for the concrete layer .
- the profiled decking sheet is pre- cambered along its length .
- a method of manufacturing the above-described assembly of a profiled decking sheet and at least one block of a lightweight material mechanically interlocked together that includes the steps of:
- the above-described assembly is a convenient form of module that can be manufactured off-site and transported to site .
- the concrete slab shown in Figure 1 includes:
- each decking sheet 3 including one flat pan 5 and side edge formations 7 that enable adjacent sheets 3 to be positioned in side by side relationship, as shown in the figure,
- the base 3 is supported by a plurality of permanent support members (not shown) .
- the main criteria for the lightweight material is that it be lightweight and form a raised platform for the concrete layer above the pans 5 and be capable of providing resistance to lateral buckling, typically inward movement, of the side edge formations 7 under load during construction stage when the profiled decking sheets function as formwork and to provide sufficient interlock to improve dynamics/damping during in service stage after the concrete has set) .
- Polystyrene foam is one of a number of suitable materials .
- the blocks 9 cover the entire upper surface of the pans 5 of the profiled decking sheets 3.
- the profiled decking sheets 3 are typically 4-9 m in length.
- the blocks 9 of the lightweight material may be the same length as the profiled decking sheets 3 or may be considerably shorter in length and positioned in end to end relationship along the entire length of each of the sheets .
- the sides of the blocks 9 are shaped to be complementary to the shapes of the side edge formations 7 so that the blocks 9 and the formations 7 are mechanically interlocked together.
- the blocks 9 sit on the pans 5 and are not adhered to or otherwise secured to the pans 5.
- the profiled decking sheets 3 are generally C- shaped and are as disclosed in International applications PCT/AUOl/01446 (WO02/38885) and PCT/AU2004/000366 (WO2004/085085) .
- the profiled decking sheets 3 include relatively high side edge formations 7 and thereby form a significant mechanical interlock with the concrete .
- each profiled decking sheet 3 and the blocks 9 of the lightweight material on the sheet 3 form a module.
- These modules can be produced off-site as part of a method of roll-forming the profiled decking sheets and thereafter be conveniently transported to a construction site.
- the profiled decking sheets 3 and the blocks 9 of the lightweight material can be separately supplied to a construction site and assembled on the site.
- the blocks of the lightweight material reduce the amount of wet concrete required and therefore reduce the overall weight of concrete slabs and lateral buckling resistance.
- the blocks of the lightweight material facilitate improved vibrations performance due to extra damping provided by the material .
- the concrete slab has comparable strength to conventional concrete slabs that do not have the blocks of the lightweight material because only concrete in tension is replaced with the lightweight material and the remaining concrete that is on top of the lightweight material is in compression under load. It is equivalent to external reinforcement - bottom pans (tensile reinforcement) are separated from concrete in compression by the lightweight material - increased capacity and stiffness of concrete slab due to increased lever arm.
- the present invention makes it possible to avoid the use of props for longer spans, minimise weight, minimise deflections, minimise slab thicknesses, and minimise concrete.
- the present invention is not so limited and extends to any suitable profiled decking sheet having multiple pans separated by internal ribs.
- the present invention is not sop limited and the side edge formations 7 may be any suitable height.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2006315015A AU2006315015A1 (en) | 2005-11-21 | 2006-11-21 | Cast in situ concrete slab |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2005906453A AU2005906453A0 (en) | 2005-11-21 | Cast in situ concrete slab | |
AU2005906453 | 2005-11-21 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2007056833A1 true WO2007056833A1 (en) | 2007-05-24 |
Family
ID=38048232
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2006/001760 WO2007056833A1 (en) | 2005-11-21 | 2006-11-21 | Cast in situ concrete slab |
Country Status (1)
Country | Link |
---|---|
WO (1) | WO2007056833A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2018093330A1 (en) | 2016-11-15 | 2018-05-24 | M Metal Pte. Ltd. | Galvanized steel deck and system thereof |
JP2018150749A (en) * | 2017-03-14 | 2018-09-27 | 日鐵住金建材株式会社 | Deck plate |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AU1016576A (en) * | 1976-01-09 | 1977-07-14 | Westeel Rosco Ltd | Composite concrete & formwork slab |
WO1996002711A1 (en) * | 1994-07-13 | 1996-02-01 | Plannja Ab | Deck with composite action |
WO1999055978A1 (en) * | 1998-04-24 | 1999-11-04 | Granstroem Anders | Floor structure |
WO2002038885A1 (en) * | 2000-11-08 | 2002-05-16 | Bhp Steel Limited | Metal decking |
US20030019177A1 (en) * | 2001-07-30 | 2003-01-30 | Kwon Heug Jin | Combination light-weight deck form, with connectors |
WO2003076095A1 (en) * | 2002-03-14 | 2003-09-18 | Bhp Steel Limited | Profiled steel decking sheets |
WO2005000496A1 (en) * | 2003-06-27 | 2005-01-06 | Bluescope Steel Limited | Profiled steel decking sheets |
JP2005205445A (en) * | 2004-01-22 | 2005-08-04 | Nisshin Steel Co Ltd | Method for manufacturing metallic heat insulating panel |
-
2006
- 2006-11-21 WO PCT/AU2006/001760 patent/WO2007056833A1/en active Application Filing
Patent Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AU1016576A (en) * | 1976-01-09 | 1977-07-14 | Westeel Rosco Ltd | Composite concrete & formwork slab |
WO1996002711A1 (en) * | 1994-07-13 | 1996-02-01 | Plannja Ab | Deck with composite action |
WO1999055978A1 (en) * | 1998-04-24 | 1999-11-04 | Granstroem Anders | Floor structure |
WO2002038885A1 (en) * | 2000-11-08 | 2002-05-16 | Bhp Steel Limited | Metal decking |
US20030019177A1 (en) * | 2001-07-30 | 2003-01-30 | Kwon Heug Jin | Combination light-weight deck form, with connectors |
WO2003076095A1 (en) * | 2002-03-14 | 2003-09-18 | Bhp Steel Limited | Profiled steel decking sheets |
WO2005000496A1 (en) * | 2003-06-27 | 2005-01-06 | Bluescope Steel Limited | Profiled steel decking sheets |
JP2005205445A (en) * | 2004-01-22 | 2005-08-04 | Nisshin Steel Co Ltd | Method for manufacturing metallic heat insulating panel |
Non-Patent Citations (1)
Title |
---|
DATABASE WPI Week 200553, Derwent World Patents Index; Class P52, AN 2005-517712 * |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2018093330A1 (en) | 2016-11-15 | 2018-05-24 | M Metal Pte. Ltd. | Galvanized steel deck and system thereof |
EP3542008A4 (en) * | 2016-11-15 | 2020-07-08 | M Metal Pte. Ltd. | Galvanized steel deck and system thereof |
JP2018150749A (en) * | 2017-03-14 | 2018-09-27 | 日鐵住金建材株式会社 | Deck plate |
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